Method of producing laminated graphics-to-glass composite back-lit panels

ABSTRACT

A method of producing a composite laminated film-to-glass panel for the display by back lighting of graphics and/or advertising and instructional alpha-numerical information for incorporation in game machines, product dispensing apparatus, and wall displays. The composite film-to-glass panel of the invention is produced by assembling as a layered structure: a primary front glass sheet component; a first intermediate mounting sheet component of double-faced adhesive-coated clear polyester film material in interfacing relationship with the front glass sheet; a second intermediate component comprised of a sheet of positive image film bearing the graphic and/or advertising and instructional information on the front side thereof in interfacing relationship with the mounting sheet component; and a rear component comprising a film-protecting sheet of clear polyester film material bearing a clear laminating adhesive on its front side in interfacing relationship with the sheet of positive image film. Heat and pressure is applied to the layered assembly of components to adhesively bond the components of the structure to form the composite laminated film-to-glass panel of the invention. The clear laminating adhesive of the rear component includes an ultraviolet light screening material.

This is a division of my application Ser. No. 08/275,681, filed Jul. 15,1994, now U.S. Pat. No. 5,443,869.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the back-lit display of graphic designsand advertising information. More particularly, the invention relates todisplay panels comprised of a primary layer of transparent sheetmaterial upon which is affixed graphic designs and/or advertising orinstructional information with such panels designed for back-litpresentation of such designs and information.

2. Description of the Prior Art

In recent years there has been an increasing utilization of back-litdisplay panels, particularly for decorative and informational use inconnection with game machines, product dispensing apparatus, and for thewall display of colorful graphics and advertising materials. Theprincipal means of satisfying such needs has been through display panelsfabricated of rigid and semi-rigid transparent plastic sheet material towhich graphic design matter and/or alpha-numerical advertising andinstructional information has been applied by classic silk screentechniques. Silk screening procedures require careful color and imageregistration and matching and such procedures are labor intensiveresulting in relatively expensive panel costs. Because of the difficultyin color-to-color registrations on plastic panel material, silk screenedmulti-color images and graphics often display fuzzy lines of coloroverlap or free-color space lines which are accentuated when the panelmaterial is subjected to back-lighting.

There have also been longevity problems with graphics-bearing plasticpanels used for game machines and product dispensing apparatus sincesuch panels are frequently subjected to physical abuse by disgruntledgame or dispenser operators and to environmental hazard through food anddrink spills. Further, the plastic sheet material and inks applied by tothe sheet material of such panels are subject to degradation over timeby ultraviolet light rays originating from the commonly utilizedfluorescent lamp type back-lighting illumination source.

It is an object of the present invention to provide improved back-litpanels for the display of graphic designs and/or advertising andinstructional information.

It is a further object of the invention to provide improved laminatedfilm-to-glass composite back-lit panels for the display of colorfulgraphics and/or alpha-numerical advertising and instructionalinformation with sharp color-to-color registration.

It is still a further object of the invention to provide unique back-litpanels comprised of a primary layer of glass upon which is affixedpositive photographic film displaying graphic designs and/or advertisingand instructional information.

It is another object of the invention to provide improved back-litpanels for the display of graphics and/or advertising and instructionalinformation comprised of a primary structural layer of glass sheetmaterial upon which is adhesively affixed photographic film includingpositive graphic imagery and/or alpha-numerical information with suchpanels being resistive to ultraviolet degradation by long-term exposureto fluorescent back-lighting.

It is still another object of the invention to provide improvedlaminated film-to-glass composite back-lit panels for decorative andinformational use in connection with game machines and productdispensing apparatus, and for the wall display of colorful graphics andadvertising materials.

Other objects and advantages of the invention will be apparent from thefollowing summary and detailed description of the invention, takentogether with the accompanying drawing figures.

SUMMARY OF THE INVENTION

The present invention relates to unique and improved laminatedfilm-to-glass composite back-lit panels for the display of graphicsand/or advertising and instructional information. The panels of theinvention are comprised of a primary layer or sheet of glass upon whichis adhesively affixed (laminated) a secondary layer or web whichincludes positive photographic film bearing graphic imagery and/oralpha-numerical information. The secondary layer is itself a compositelaminated web comprised of: a) an intermediate layer of the positivephotographic film; b) a first outer layer of double-facedadhesive-coated optically clear polyester film material affixed byadhesive action to the image side of the photographic film; and c) asecond outer layer of single-faced adhesive-coated clear ultravioletscreening plastic film material affixed by adhesive action to reverseside of the photographic film. The secondary layer, including thepositive image photographic film, is adhesively affixed to the primarylayer (glass sheet) after the glass has been thoroughly cleaned andfreed of any and all dust particles on or embedded in the interfacedsurface thereof.

To form the secondary layer of a laminated composite graphics panel ofthe invention, a web of positive image photographic film of highestquality and sensitivity is exposed to the projected imagery which it isdesired to display by back-lighting. The film is appropriatelydeveloped, fixed and dried in a closed dust-free environment andimmediately passed to a laminating station including a first pressurenip formed between two pressure rolls. Fed to such pressure nip, at theimage side of the photographic film, is a web of double-facedadhesive-coated polyester film material from which has been removed afirst adhesive protective release cover material on the adhesive sidethereof which is to be interfaced with the photographic film through thepressure nip. The first release cover material is remove from thepolyester film just prior to its entry into the pressure nip. Also fedto such pressure nip, at the back side of the photographic film, is aweb of single-faced adhesive-coated ultraviolet screening plastic filmmaterial from which has been removed the adhesive protective releasecover material on the adhesive side thereof which is to be interfacedwith the photographic through the pressure nip. Again, the release covermaterial is removed from the UV screening film just prior to its entryinto the pressure nip.

The secondary composite laminated layer or web (including the positivephotographic film) leaving the first pressure nip has a second adhesiveprotective release cover material removed from the polyester filmmaterial and is fed into a second pressure nip formed between a set oftwo heated pressure rolls. Also fed into the second pressure nip forinterfacing adhesion to the secondary layer is a primary layer or sheetof clean glass. The heat of the pressure rolls of the second pressurenip and the pressure applied to the interfaced glass sheet material andthe film encompassing composite secondary layer by such rolls assurespermanent adhesion of the secondary layer to the glass primary layer ofthe ultimate laminated film-to-glass composite panel of the invention.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is an enlarged cross-sectioned view of a composite laminatedsection of a film-to-glass back-lit panel in accordance with the presentinvention;

FIG. 1a is an exploded cross-sectioned view of the composite laminatedpanel section of FIG. 1 showing the adhesive surfaces of the componentsof the panel;

FIG. 1b is an enlarged cross-sectioned view of the double-facedadhesive-coated polyester film material used to affix the image side ofthe photographic film of the panel of FIG. 1 to the glass layer of thepanel before removal of the release sheet of material initially coveringand protecting the adhesive coatings of the polyester film material;

FIG. 1c is an enlarged cross-sectioned view of the single-facedadhesive-coated plastic film material affixed to the back side of thephotographic film of the panel of FIG. 1 for the film-protectivescreening-out of ultraviolet light from the back-lighting source, suchplastic film UV screening material being shown before removal of therelease sheet material initially covering and protecting the adhesivecoating of such screening material;

FIG. 2 is a somewhat diagrammatic showing of one method of fabricatingin a continuous fashion the film-to-glass back-lit display panels of thepresent invention; and

FIG. 3 is a somewhat diagrammatic showing of a second method offabricating in panel-by-panel fashion the film-to-glass back-lit displaypanels of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

Referring initially to FIGS. 1 and 1a of the drawing sheets, there isshown, first in enlarged cross-section and then in explodedcross-section, a film-to-glass composite laminated panel 10 which, inaccordance with the present invention, is highly suited for the back-litdisplay of graphic designs and/or advertising and instructionalinformation. The composite laminated panel 10 is comprised of a glassface sheet 12, a sheet of optically clear double-faced adhesive-coatedpolyester film material 14, photographic image-bearing film 16, and asheet of single-faced adhesive-coated plastic film material 18 whichprotects the photographic film from degradation by screening outultraviolet light rays which may be projected onto the rear side of thepanel by a back-lighting source.

The FIG. 1a exploded cross-section view of the panel 10 of FIG. 1 showsin greater detail that the double-faced adhesive-coated polyester filmlayer 14 of the composite panel includes a sheet of polyester filmmaterial 14a which bears an adhesive coating 14b on the side thereofwhich adhesively interfaces with the glass face sheet 12. The polyesterfilm layer 14 also bears an adhesive coating 14c on the side thereofwhich adhesively interfaces with the photographic film 16 comprised offilm material 16a with its images imprinted on the image side 16bthereof. FIG. 1a also shows that the single-faced adhesive-coated UVscreening plastic film material 18 is comprised of UV screening material18a which bears an adhesive coating 18b on the side thereof whichadhesively interfaces with the rear side of the photographic filmmaterial 16a.

FIG. 1b is an enlarged cross-sectioned view of the double-facedadhesive-coated polyester film material 14 prior to its application tothe photographic film 16 and glass face sheet 12. As shown, thepolyester film material per se 14a bears an adhesive coating 14b on theside of such film material that is to be adhesively interfaced withglass face sheet 12 and an adhesive coating 14c on the side thereof thatis to be adhesively interfaced with the photographic film 16a. Theadhesive coatings 14b and 14c on polyester film material 14a areinitially protected, respectively, by sheets of removable adhesiverelease material 14d and 14e. The sheets of release material 14d and 14emay be of any of several known varieties including wax paper releasesheeting material and silicone coated plastic release sheeting material.

FIG. 1c is an enlarged cross-sectioned view of the single-facedadhesive-coated plastic film material 18 prior to its application to therear side of photographic film material 16a to provide UV screeningprotection to the photographic film and its imagery, As shown, theplastic UV screening material per se 18a bears an adhesive coating 18bon the side thereof that is to be adhesively interfaced with thephotographic film material 16a. The adhesive coating 18b on screeningmaterial 18a is initially protected by a sheet of removable releasematerial 18c. As in the case of the double-faced adhesive-coatedpolyester film material 14, the protective sheet of removable releasematerial 18c may be of any of several known varieties.

Referring now to FIG. 2 of the drawing sheets, there is shown (in asomewhat diagrammatic form) a continuous method of fabricating thefilm-to-glass back-lit panels of the present invention. Positivephotographic film 16 bearing graphic designs and/or advertising orinstructional information is generated in film production station 20.The film production station 20 includes an image projection device 22which applies the desired design and/or information imagery to unexposedfilm (from film spool 30) which moves through the film exposure section24 of the station 20. Exposed film is developed, washed and fixed in anappropriate series of film developing and washing sections 26a, 26b . .. 26n with the developed and fixed positive image film dried in a finalfilm drying section 28 of film production station 20. During its travelthrough the film developing and washing sections of film productionstation 20 the film is moved from section to section in looping fashionover a multiplicity of film guide rolls 32 and a final guide roll 34 ofthe film drying section 28. Within the developing and washing sections26a, 26b . . . 26n the film in sequence is downwardly looped for passagethrough developing and washing baths 36a, 36b . . . 36n. The strip orweb 16 of processed positive image-bearing film leaving the filmproduction station 20 is comprised of the film material 16a with theimage side of the film indicated as 16b.

The film strip 16 is next fed to a pressure nip 46 formed betweenpressure rolls 48 and 50 wherein the film strip 16 is sandwichedbetween: a) a mounting strip or web of the double-faced adhesive-coatedpolyester film material 14 used to affix the image side 16b of thephotographic film 16a to the glass layer of the back-lit panel structureof the invention; and b) a strip or web of the single-facedadhesive-coated UV screening plastic film material 18 to be affixed tothe back side of the photographic film 16a. The double-facedadhesive-coated polyester film material 14, as derived from its supplyroll (not shown), bears on each of its sides overlay release sheetmaterial 14d and 14e to protect the adhesive coatings. As the mountingweb of polyester film material 14 passes over guide roll 38 on its wayto the pressure nip 46 its release sheet material 14e (covering theadhesive coating 14c to be interfaced with image side 16b of thephotographic film 16a) is removed and wound onto overlay collection roll40. The single-faced adhesive-coated UV screening plastic film material18, as derived from its supply roll (not shown), bears on its adhesivecoated side overlay release sheet material 18c to protect the adhesivecoating 18b of the material 18a per se. As the web of UV screening filmmaterial 18 passes over guide roll 42 on its way to the pressure nip 46the release sheet material 18c (covering the adhesive coating 18b to beinterfaced with non-image side of the photographic film 16a) is removedand wound onto overlay collection roll 44. As a result of passagethrough the pressure nip 46, the mounting web 14, intermediatephotographic film strip 16, and web of UV screening film material 18 areformed into a composite laminated strip or web of material 14a-16a-18 awith the 14a polyester mounting material bearing on its outer surfaceadhesive coating 14b protected by overlay release sheet material 14d.

The composite laminated web of material 14a-16a-18a moves over guideroll 52 to a panel assembly station 60 wherein such web is fed to apressure nip 58 formed between heated pressure rolls 62 and 64. Prior toentering the pressure nip 58 the composite laminated web 14a-16a-18apasses between guide roll 54 and pressure roll 62 and the protectiveoverlay release sheet material 14d is removed from the adhesive coating14b of the mounting web 14a and wound onto overlay collection roll 56.The composite laminated web 14a-16a-18a is interfaced with a sheet ofglass 12 (supported by and moved along glass feed table 66) with theexposed adhesive coating 14b pressed into adhering relationship to theglass as the interfaced web and glass sheet enter and pass through thepressure nip 58 formed between pressure rolls 62 and 64. The completelyfabricated composite laminated film-to-glass panel 10 of the inventionthereafter is moved to a laminate receiving table 68 by the forwarddriving action of the pressure rolls 62 and 64. Distinct graphic and/orinformational sections of the completed composite panel 10 may beappropriately separated from one-another by known glass cutter means.

As an alternative to the back-lit panel fabrication method shown in FIG.2, and described hereinbefore, distinct composite laminatedfilm-to-glass back-lit panels, in accordance with the present invention,may be fabricated in independent sections as shown in FIG. 3. Thus,distinct sections of the composite laminated web material 14a'-16a'-18a'(including an intermediate layer of positive photographic film 16a') ofspecific length and width dimensions may be interfaced with a glasssheet 12' (of matching length and width dimensions) and run through apressure nip 58' formed between heated pressure rolls 62' and 64'. Thecomposite laminated web material 14a'-16a'-18a' (with the overlay ofrelease material 14d' protecting the adhesive coating on the mountingweb 14a') is laid over pressure roll 62' with the leading edge of suchcomposite laminated web material matched to the leading edge of glasssheet 12' (supported on glass feed table 66'). The release material 14d'is slightly pulled back so that the leading edge of the adhesive coatingon mounting web 14a' is exposed and interfaced with the edge of theglass sheet. When proper alignment of the composite laminated webmaterial 14a'-16a'-18a' with the glass sheet is attained the webmaterial and glass sheet are introduced to the pressure nip 58' and asthe web material and glass sheet are pulled through the pressure nip bythe rolls 62' and 64' the release material is pulled off of the webmaterial and discarded. The completely fabricated composite laminatedfilm-to-glass panel 10' of the invention, after its passage betweenpressure rolls 62' and 64' is moved to a laminate receiving table 68'.To assure adequate web-to-glass adherence, the composite laminated panel10' may be run through the pressure nip 58' a second or third time.

EXAMPLE

A broad selection of laminated film-to-glass composite back-lit panelsfor the display of graphics and/or advertising and instructionalinformation have been fabricated in accordance with the presentinvention. For example, a most suitable composite graphics panel forback-lit use in game machines has consisted of: a panel face sheet ofglass of 3/16 inch thickness, a film mounting sheet of "FLEXmark" branddouble-faced adhesive-coated polyester film material supplied byFLEXcon, a sheet of "ILFOCHROME" positive-image color photographicdisplay film manufactured by Ilford, and a rear polyester sheet ofsingle-faced adhesive-coated "Filmolux" brand overlaminate ultravioletscreening material supplied by Interlam, Inc.

The film mounting sheet of double-faced adhesive-coated polyester film,intermediate sheet of positive image-bearing photographic display film,and single-faced adhesive-coated UV screening overlaminate were firstlaminated, in accordance with the invention, by passage of thesematerials together through a pressure nip comprised of mating pressurerolls. The adhesive coatings of the mounting polyester film and UVscreening overlaminate, prior to their interfacing lamination to thephotographic display film, were freed of their respective protectiverelease liners of silicone coated polyester film. The solvent basedacrylic adhesive of the polyester overlaminate layer included as the UVscreening additive 2,2',4,4'-Tetrahydroxybenzophenone to provide, by theoverlaminate, protection of the photographic display film from anyharmful UV radiation from the panel's back-lighting source when thepanel is in place on the face structure of a game machine.

Following the lamination of the mounting polyester film, intermediatephotographic display and UV screening overlaminate, the resultingthree-part composite was laminated under pressure and mild heat(approximately 47 degrees C or 120 degrees F) to the face sheet of glassof comparative size to form the completed back-lit panel. Prior to finallamination of the three-part composite to the sheet of glass the glasswas thoroughly cleaned with an ammonia based glass cleaner, such as"Windex" cleaner produced by 8C Johnson, and freed of any and all dustparticles on or embedded in the interfaced surface thereof. Also, priorto final lamination, the adhesive coating on the glass interfacing sideof the three-part composite was freed of its protective release liner.

In the specification and drawing figures there has been set forthpreferred embodiments of the invention and although specific terms havebeen employed, they are used in a generic and descriptive sense only andnot for the purpose of limitation, the scope of the invention beingdefined in the following claims.

What is claimed is:
 1. A method of producing a composite laminatedfilm-to-glass panel for the display by back-lighting of graphic designsand/or advertising and instructional alpha-numerical information forincorporation in game machines, product dispensing apparatus and walldisplays which comprises:a) assembling as a composite pre-laminated rearlayered component of said panel: i) a mounting sheet of opticallytransparent plastic film material bearing a clear laminating adhesivematerial on the front and rear surfaces thereof, said adhesive materialon said front surface of said mounting sheet being protected by a sheetof release material; ii) an intermediate sheet of positive image filmbearing said graphic designs and/or alpha-numerical information, theimage side of said positive image film being interfaced with thelaminating adhesive on the rear surface of said mounting sheet; and iii)a film-protecting sheet of optically transparent plastic film materialbearing on its front surface a clear laminating adhesive includingultraviolet light screening material, the rear side of said sheet ofpositive image film being interfaced with the clear laminating adhesiveon the front surface of said film-protecting sheet; b) applying pressureto the assembly of said mounting sheet, intermediate sheet of positiveimage film, and film-protecting sheet to adhesively bond said sheets toone-another and form the composite pre-laminated rear layered componentof said panel; c) removing the sheet of adhesive protecting releasematerial from the front adhesive surface of said mounting sheet of saidcomposite rear layered component and interfacing said layered componentat the adhesive surface of said mounting sheet with a sheet of glasscomprising the front face component of said panel; and d) applyingpressure and heat to the interfaced composite pre-laminated rear layeredcomponent and the glass front face component to adhesively bond saidface component to said rear layered component to form said compositelaminated film-to-glass panel.
 2. The method of producing a compositelaminated film-to-glass panel as claimed in claim 1 wherein the plasticfilm material of said mounting sheet and the plastic film material ofsaid film-protecting sheet are polyester film materials.
 3. The methodof producing a composite laminated film-to-glass panel as claimed inclaim 1 wherein the sheet of glass comprising the front component ofsaid panel is thoroughly cleaned with an ammonia based glass cleaner andfreed of all dust particles on, or embedded in, the surface thereof tobe interfaced with and adhered to the composite pre-laminated rearlayered component of said panel.
 4. The method of producing a compositelaminated film-to-glass panel as claimed in claim 1 wherein pressure andheat are applied to the interfaced composite pre-laminated rear layeredcomponent and the glass front component to adhesively bond said facecomponent to said rear layered component by passing said interfaced rearlayered component and said glass component between opposed heatedrollers.
 5. The method of producing a composite laminated film-to-glasspanel as claimed in claim 4 wherein the opposed heated rollers areheated to a temperature of approximately 47 degrees C (120 degrees F).6. A method of producing a composite laminated film-to-glass panel forthe display by back-lighting of graphic designs and/or advertising andinstructional alpha-numerical information for incorporation in gamemachines, product dispensing apparatus and wall displays whichcomprises:a) assembling as a layered composite structure:i) a sheet ofglass comprising the front face component of said panel; ii) a mountingsheet of optically transparent plastic film material comprising thefirst intermediate component of said panel and bearing a clearlaminating adhesive material on the front and rear surfaces thereof, thefront surface of said mounting sheet and its laminating adhesive beinginterfaced with said sheet of glass; iii) a sheet of positive image filmbearing on its front side said graphic designs and/or alpha-numericalinformation comprising the second intermediate component of said panel,the front side of said positive image film being interfaced with thelaminating adhesive on the rear surface of said mounting sheet; and iv)a film-protecting sheet of optically transparent plastic film materialcomprising the rear component of said panel and bearing on its frontsurface a clear laminating adhesive which includes an ultraviolet lightscreening material, the front surface of said film-protecting sheet andits laminating adhesive being interfaced with the rear side of saidpositive image film; and b) applying pressure and heat to said layeredcomposite structure to adhesively bond the components of said structureto form said composite laminated film-to-glass panel.